CN114126562B - Multi-layer absorbent core and method of making the same - Google Patents

Abstract

The invention discloses a multilayer absorbent body and a method of manufacturing the same. The method of forming an absorbent body may include: moving the first cover material in a longitudinal direction; moving a reinforcing material along the longitudinal direction and bonding the reinforcing material with the first cover material, the reinforcing material having a top side and a bottom side; applying an absorbent material comprising superabsorbent particles to the top side of the reinforcing material; moving a second cover material along the machine direction and bonding the second cover material with the first cover material and the reinforcing material to form a laminate structure of the first cover material, the reinforcing material, and the second cover material, wherein the first cover material is disposed below the reinforcing material and the second cover material is disposed on top of the reinforcing material; and embossing the laminate structure.

Description

Multilayer absorbent core and method of manufacturing same

Technical field

The present disclosure relates to absorbent bodies, and more particularly to layered absorbent bodies for use in, for example, absorbent articles.

Background technique

People rely on disposable absorbent products in their daily lives, including articles such as adult incontinence products, bedwetting pants, training pants and diapers. Many manufacturers strive to better meet user needs for such products. For example, the fit, fit and leakage protection of many products need to be further improved.

An important component of many absorbent articles is the absorbent body, such as the absorbent core, contained in such articles. These absorbent bodies are typically responsible for capturing and retaining liquid body exudates, thereby preventing the exudates from leaking from the absorbent article, and further keeping liquids away from the wearer's skin, which helps promote skin health. Improving the structure and performance of absorbent bodies to produce thinner products that absorb liquids faster and leak less is a continued important area of market demand.

Contents of the invention

The present disclosure relates to absorbent bodies, and more particularly to layered absorbent bodies for use in, for example, absorbent articles.

In a first embodiment, a method of forming an absorbent body may include: moving a first cover material longitudinally, the first cover material having a top side and a bottom side; moving a reinforcing material longitudinally, and combining the reinforcing material with the first cover material Combined, the reinforcing material has a top side and a bottom side; applying an absorbent material containing superabsorbent particles to the top side of the reinforcing material; moving a second covering material longitudinally, the second covering material having a top side and a bottom side, and placing The second covering material is combined with the first covering material and the reinforcing material to form a laminate structure of the first covering material, the reinforcing material and the second covering material, wherein the first covering material is disposed under the reinforcing material, and the second covering material is disposed on top of the reinforcement; and embossing the laminate structure.

In a second embodiment, the absorbent body may include: a liquid permeable top cover material; a bottom cover material; a reinforcement material disposed between the top cover material and the bottom cover material; and a superabsorbent material, the superabsorbent material The material is disposed within the reinforcement material in a pattern of high SAM concentration areas and low SAM concentration areas.

The above summary of the present disclosure is not intended to describe each embodiment or every implementation of the present disclosure. The advantages and achievements, and a more complete understanding of the present disclosure, will be apparent and understood by reference to the following detailed description and claims taken in conjunction with the accompanying drawings.

Description of the drawings

The present disclosure may be more fully understood in view of the following detailed description of various embodiments taken in conjunction with the accompanying drawings, in which:

Figure 1 is a perspective view of an exemplary absorbent article in a closed configuration in accordance with aspects of the present disclosure;

Figure 2 is a plan view of the absorbent article of Figure 1 in an open and lay-down configuration;

Figure 3 is a cross-section of an exemplary absorbent body in accordance with aspects of the present disclosure;

Figure 4 is a schematic diagram of an exemplary method for forming an absorbent body of the present disclosure;

Figure 5 is a schematic diagram of an exemplary method for embossing the absorbent body of the present disclosure;

Figure 6A is a top plan view of a portion of an exemplary embossing surface that may be used in the embossing method of Figure 5;

Figure 6B is a side view of a portion of an exemplary embossing surface that may be used in the embossing method of Figure 5;

7 is a photograph of an unembossed reinforcement material containing superabsorbent particles in accordance with aspects of the present disclosure;

8 is a photograph of an embossed reinforcement material containing superabsorbent particles in accordance with aspects of the present disclosure;

Figure 9 is a schematic diagram of an exemplary method for forming an absorbent body of the present disclosure; and

Figure 10 is a cross-section of an exemplary absorbent body in accordance with aspects of the present disclosure.

Although the present disclosure allows various modifications and alternative forms, the details thereof have been shown in the drawings by way of example and will be described in detail. However, it should be understood that it is not intended to limit the various aspects of the present disclosure to the specific embodiments described. On the contrary, it is intended to cover all modifications, equivalents and alternative forms that fall within the scope of the present disclosure.

Detailed ways

The following description should be read with reference to the accompanying drawings, in which similar elements in different figures have the same numbering. The description and drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the disclosure.

Although certain suitable dimensions, ranges and/or values are disclosed in connection with various components, features and/or specifications, those skilled in the art to which this disclosure relates will understand that the desired dimensions, ranges and/or values may deviate from Those that are explicitly disclosed.

Each example is given by way of illustration and is not meant to be limiting. For example, a feature illustrated or described as part of one embodiment or drawing can be used on another embodiment or drawing to produce yet another embodiment. It is intended that this disclosure incorporate such modifications and changes.

When introducing elements of the disclosure or preferred embodiments thereof, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements. Many modifications and variations may be made in this disclosure without departing from its spirit and scope. Therefore, the above-described exemplary embodiments should not be used to limit the scope of the present invention.

In the context of this specification, each term or phrase below will include one or more of the following meanings. Additional terms are defined elsewhere in the specification.

"Absorbent article" or "absorbent garment" as used herein means a device that is placed against or proximate the body of the wearer (i.e., adjacent the body) to absorb and contain various liquid, solid and semi-solid exudates from the body products of things. Absorbent articles such as those described herein are intended to be discarded after a limited period of use and not to be laundered or otherwise recovered for reuse. It should be understood that the present disclosure is applicable to a variety of disposable absorbent articles, including but not limited to diapers, training pants, youth pants, swimming trunks, and incontinence products, without departing from the scope of the disclosure.

"Airlaid" as used herein refers to webs manufactured by the airlaid process. In the airlaid process, bundles of small fibers with typical lengths ranging from about 3 to about 52 mm are separated and entrained in an air source and then deposited onto a forming screen, typically with the aid of a vacuum source. The randomly deposited fibers are then bonded to each other using, for example, hot air to activate the binder component or latex adhesive. Airlaid is taught, for example, in U.S. Patent No. 4,640,810 to Laursen et al., which is incorporated by reference in its entirety for all purposes.

"Coupled" refers to the joining, adhesion, connection, attachment, etc., of two elements. Two elements will be said to be bonded together when they are engaged, adhered, connected, attached, etc., directly to each other or indirectly to each other, such as when bonded to an intermediate element. Bonding can be performed, for example, by adhesives, pressure bonding, thermal bonding, ultrasonic bonding, splicing, stitching and/or welding.

"Bonded carded web" as used herein refers to a web made of short fibers that are conveyed through a combing or carding unit that separates or breaks the staple fibers and aligns them in the machine direction to form a generally Nonwoven web of fibers oriented in the machine direction. The materials may be bonded together by methods that may include point bonding, through-air bonding, ultrasonic bonding, adhesive bonding, and the like.

"Coform" as used herein refers to a composite material that includes a mixture or stabilizing matrix of thermoplastic fibers and a second non-thermoplastic material. For example, coform materials can be made by a process in which at least one meltblown die is positioned adjacent a chute through which other materials are added to the web while it is being formed. Such other materials may include, but are not limited to, fibrous organic materials, such as wood or non-wood pulps, such as cotton, rayon, recycled paper, pulp fluff, as well as superabsorbent particles, inorganic absorbent materials and/or organic absorbent materials, treated Polymer short fibers, etc. Some examples of such coform materials are disclosed in U.S. Patent No. 4,100,324 to Anderson et al., U.S. Patent No. 4,818,464 to Lau, U.S. Patent No. 5,284,703 to Everhart et al., and U.S. Patent No. 5,350,624 to Georger et al. , each of these patents is incorporated by reference in its entirety for all purposes.

"Connected" refers to the joining, adhesion, bonding, attachment, etc., of two elements. Two elements will be considered to be connected together when they are connected directly to each other or indirectly to each other, such as when each element is directly connected to an intervening element.

"Disposable" means an article designed to be discarded after limited use rather than laundered or otherwise repaired for reuse.

"Provided", "Proposed on" and their variations are intended to mean that one element can be integral with another element, or that one element can be coupled to or placed with another element or placed on A separate structure near another element.

"Elastic", "elastomeric" and "elastic" mean the property of a material or composite by which it tends to return to its original size and shape after the force causing the deformation is removed.

"Elastomer" refers to a material or composite that can elongate at least 50% of its relaxed length and will regain at least 20% of its elongation upon release of an applied force. It is generally preferred that the elastomeric material or composite is capable of elongating at least 50% of its relaxed length, more preferably at least 100%, still more preferably at least 300%, and resumes its elongation upon release of the applied force. At least 50% of the length.

"Fibrous absorbent material" or "absorbent fiber" as used herein means natural fibers; cellulosic fibers; synthetic fibers composed of cellulose or cellulose derivatives, such as man-made fibers; inorganic fibers composed of intrinsically wettable materials , such as glass fibers; synthetic fibers made of intrinsically wettable thermoplastic polymers, such as certain polyester or polyamide fibers, or synthetic fibers made of non-wettable thermoplastic polymers, such as those that have been wetted by suitable means. Water-based polyolefin fiber. For example, by treatment with surfactants, treatment with silica, treatment with materials having suitable hydrophilic moieties that are not easily removable from the fibers, or by treating non-wettable materials with hydrophilic polymers during or after fiber formation. The hydrophobic fiber coating can make the fiber hydrophilic.

When used in the singular, "layer" may have the dual meaning of a single element or a plurality of elements.

"Machine direction" (MD) refers to the length of a fabric in the direction in which it is made, as opposed to "cross direction" (CD), which refers to the width of the fabric in a direction generally perpendicular to the machine direction.

When used in the singular, "member" may have the dual meaning of a single element or a plurality of elements.

"Nonwoven fabric" or "nonwoven web" as used herein refers to a web having a structure of individual fibers or threads that are interwoven, but not in an identifiable pattern as in knitted fabrics. Intertwined ways. Nonwoven fabrics or webs have been formed by many processes, such as meltblown, spunbond, through air bonded carded web (also known as BCW and TABCW) processes, etc.

"Spunbond web" as used herein refers to a web containing small diameter substantially continuous fibers. The fibers are formed by extruding molten thermoplastic material from the capillary tubes of a plurality of thin, generally circular spinnerets having the diameter of the extruded fibers, and then by eductive drawing and /or other well-known spunbond mechanisms that rapidly taper. Spunbond webs are prepared, for example, in U.S. Patent No. 4,340,563 to Appel et al., U.S. Patent No. 3,692,618 to Dorschner et al., U.S. Patent No. 3,802,817 to Matsuki et al., U.S. Patent No. 3,338,992 to Kinney, and U.S. Patent No. 3,338,992 to Kinney. No. 3,341,394, U.S. Patent No. 3,502,763 to Hartman, U.S. Patent No. 3,502,538 to Levy, U.S. Patent No. 3,542,615 to Dobo et al., and U.S. Patent No. 5,382,400 to Pike et al., the entire contents of which are incorporated by reference. incorporated herein for all purposes. Spunbond fibers are generally non-tacky when deposited onto a collection surface. Spunbond fibers can sometimes have a diameter of less than about 40 microns, and typically between about 5 and about 20 microns.

"Superabsorbent polymer", "superabsorbent material", "SAP" or "SAM" shall be used interchangeably and shall refer to a polymer that can absorb and retain extremely large amounts of liquid relative to its own mass. Water-absorbing polymers are classified as cross-linkable hydrogels that absorb aqueous solutions through hydrogen bonding and other polar forces with water molecules. The ability of SAP to absorb water is based in part on the degree of ionization (a coefficient of ion concentration in an aqueous solution) and the functional polar groups of the SAP that have water affinity. SAP is typically made by the polymerization of acrylic acid blended with sodium hydroxide in the presence of an initiator to form the sodium salt of polyacrylate (sometimes called sodium polyacrylate). Other materials are also used to prepare superabsorbent polymers, such as polyacrylamide copolymers, ethylene maleic anhydride copolymers, croscarmellose, polyvinyl alcohol copolymers, cross-linked polyethylene oxide, and polyacrylonitrile Starch graft copolymer. SAP can be present in the absorbent garment in particulate or fiber form or as a coating or another material or fiber.

When used in conjunction with the term "superabsorbent polymer," "particles," "particulate matter" and the like refer to the form of discrete units. The units may include flakes, fibers, aggregates, granules, powders, spheres, powdered materials, etc., and combinations thereof. The particles can have any desired shape: for example, cubes, rod-shaped polyhedrons, spheres or hemispheres, circles or semicircles, corners, irregulars, etc.

"Particulate superabsorbent polymer" and "particulate superabsorbent polymer composition" mean superabsorbent polymers and superabsorbent polymer compositions in discrete form, where "particulate superabsorbent polymer" and "particulate superabsorbent polymer The "polymer composition" may have a particle size of less than 1000 microns or from about 150 microns to about 850 microns.

"Polymer" includes, but is not limited to, homopolymers, copolymers (eg, block, graft, random and alternating copolymers, terpolymers, etc.), and blends and modified forms thereof. Furthermore, unless otherwise specifically limited, the term "polymer" shall include all possible geometric isomers of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic symmetries.

Unless otherwise stated herein, "% by weight" or "%wt" as used herein and referring to a component of a dry particulate superabsorbent polymer composition is to be interpreted as based on the weight of the dry superabsorbent polymer composition.

These terms may be defined using additional language in the remainder of the specification.

Referring to FIGS. 1-2 , the garment 20 extends along a longitudinal direction 23 and a lateral direction 22 perpendicular to the longitudinal direction 23 . As used in describing various embodiments of garment 20, the terms "longitudinal" and "lateral" have their customary meanings in accordance with aspects of the present disclosure, as indicated by central longitudinal axis 24 and central lateral axis 25 of. The central longitudinal axis 24 lies in the plane of the garment when it is in the fully stretched and flat position with the front and back panels separated, and is generally parallel to the line bisecting the left and right body halves of a standing wearer when the garment is worn. vertical plane. The central lateral axis 25 lies in the plane of the garment and is generally perpendicular to the central longitudinal axis 24 . Garment 20 has a front region 30 defining a front waist end edge 32, a back region 34 defining a rear waist end edge 36, and a crotch region 38 positioned longitudinally between the front region 30 and the back region 34. The crotch region 38 defines two laterally opposing crotch side edges 39 . The garment 20 defines a garment length 21 extending from the front waist end edge 32 to the rear waist end edge 36 .

The garment 20 includes a front panel 40 defining a front panel leg edge 44 spaced longitudinally inwardly from the front waist end edge 32 and first and second laterally opposed front panel side edges 46, 48. The garment 20 also includes a back panel 41 defining a back panel leg edge 45 spaced longitudinally inwardly from the back waist end edge 36 and first and second laterally opposed back panel side edges 47, 49. "Longitudinal inward (or inward)" as used herein to describe garment embodiments means in a direction longitudinally toward the central lateral axis 25. Likewise, "laterally inward (or medial)" as used herein to describe garment embodiments means in a direction laterally toward the central longitudinal axis 24. The front panel 40 is longitudinally spaced apart from the rear panel 41 . The front and back panels 40 generally include elastic materials to conform to the wearer's body.

A pair of side seams 84, 84 connect the front region 30 to the back region 34 such that the garment 20 defines a waist opening 27 and a pair of leg openings 28. The side seams may be permanent but tearable, such as by adhesive, heat, pressure or ultrasonic bonding, or more easily releasable and refastenable, such as by the use of mechanical fastening elements.

The garment 20 may also include at least one front leg elastic member 70 disposed adjacent the front panel leg edge 44 and/or at least one back leg elastic member 75 disposed adjacent the back panel leg edge 45 . Such leg elastic members 70 and/or 75 help provide additional elastic support around the leg opening 28 to enhance the fit and leakage protection of the garment 20 . Each leg elastic member 70, 75 may comprise a single band, strand or thread (or the like) of elastic material, or each may comprise two, three or more bands, strands or threads (or the like) of elastic material ( or similar). In certain embodiments, the rear leg elastic members 75 and/or the front leg elastic members 70 extend laterally across the entire width of the garment. In other embodiments, such as those representatively shown in Figures 1 and 2, the rear leg elastic members 75 may include a pair of rear leg elastic members, such as a first one positioned on opposite sides of the absorbent composite 50. Rear leg elastic member 76 and second rear leg elastic member 77 . Similarly, the front leg elastic members 70 may include a pair of front leg elastic members, such as a first front leg elastic member 71 and a second front leg elastic member 72 positioned on opposite sides of the absorbent composite 50 . In preferred embodiments, such as those representatively shown in FIGS. 1 and 2 , each rear leg elastic member 75 may include a plurality of elastomeric strands, and/or each front leg elastic member 70 Multiple elastomeric strands may be included.

In certain embodiments, absorbent composite 50 is attached to and between the front panel 40 and the back panel 41 . The absorbent composite 50 may include a liquid-impermeable barrier layer 52 defining a width 53 and a length 51 , an absorbent body 54 (sometimes referred to herein as an absorbent core) containing absorbent material, a liquid-permeable liner 55 and/or a gusset A composite structure formed by elastic members 56. As used herein, the term "absorbent material" may mean a fibrous absorbent material, a superabsorbent material (SAM), or a combination of both fibrous absorbent material and SAM. In some embodiments, the absorbent body 54 may include a layered structure that includes multiple zones of liquid-absorbent material, such as fibrous absorbent materials and/or SAM. The absorbent body 54 defines a length 61 and a width 63. The exemplary absorbent body 54 of the present disclosure is further described below with reference to FIG. 3 .

It should be understood that the exemplary pant-like garment 20 is only one possible example of an absorbent garment that may be used with the described absorbent body 54 of the present disclosure. Such garments 20 as shown in Figures 1 and 2 may generally be described as garments formed using a cross-machine (CD) manufacturing process. Alternative exemplary garments that may be used with the absorbent body 54 described may include those formed by a machine direction (MD) manufacturing process. In general, this disclosure is not meant to be limited to the specifically disclosed absorbent garments. Rather, the described absorbent body 54 may be used within any suitable backsheet construction for retaining the described absorbent body 54 on the wearer's body. In even further contemplated embodiments, the absorbent body 54 described may be used with no backsheet structure at all. Instead, the absorbent body 54 may be configured to be in direct contact with the wearer's body - such as using a body adhesive disposed on the body side surface of the absorbent body 54 .

Figure 3 depicts an exemplary cross-section of the absorbent body 54 of Figure 2 as viewed along line 3-3. Generally speaking, the absorbent body 54 of the present disclosure may include a variety of different materials, some of which are laminated together to form the body 54.

Describing the specific embodiment of the absorbent body 54 shown in Figure 3, the exemplary absorbent body 54 includes a bottom cover material 101 and a top cover material 103, both disposed around a reinforcement material 116. The absorbent body 54 may also include a core wrap material 120, which is optional in some embodiments.

Bottom cover material 101 and top cover material 103 may be formed from any suitable material. At least the top cover material 103 may be liquid permeable and may perform well in absorbing and wicking fluids. In some embodiments, the bottom cover material 101 may also be liquid permeable and perform well at absorbing and wicking fluids. However, in other embodiments, the bottom cover material 101 may be liquid impermeable to help prevent liquid leakage from the body 54 .

Cover materials 101 and/or 103 may include natural and synthetic fibers such as, but not limited to, polyester, polypropylene, acetate, nylon, polymeric materials, cellulosic materials, and combinations thereof. In various embodiments, cover materials 101 and/or 103 may be hydrophobic and may be treated to become hydrophilic in any manner known in the art. Some exemplary suitable materials include tissue materials, spunbond and/or meltblown materials (e.g., spunbond-meltblown materials and spunbond-meltblown-spunbond materials), spunlace materials, Materials, which are commercially available from Kimberly-Clark World Wide, Inc., airlaid materials, through air bonded carded webs (TABCW) and coform materials. The cover materials 101, 103 may have a basis weight ranging between about 5 grams per square meter (gsm) and about 55 gsm. According to some specific embodiments of the present disclosure, the top cover material 103 may be a tissue, SMS, or spunbond material with a basis weight between about 7 gsm and about 20 gsm. In other embodiments, the top cover material 103 may be a coform, spunlace, or airlaid material with a basis weight between about 35 gsm and about 55 gsm. According to other specific embodiments of the present disclosure, the bottom cover material 101 may be coform, spunlace, airlaid, or/> with a basis weight between about 30 gsm and about 50 gsm. Material. However, these are just some examples. In other embodiments, other suitable materials and/or materials with basis weights different from the above identified ranges may be used.

Reinforcement material 116 may help provide some structural integrity to body 54 and aid in fluid absorption and distribution. Another benefit of the reinforcement material 116 is that it may help stabilize the absorbent material within the absorbent body 54 , such as the absorbent material embedded within the reinforcement material 116 . Generally speaking, reinforcement material 116 may include a nonwoven material composed of a plurality of individual fibers 117 . For example, reinforcement material 116 may be a spunbond material or a spunbond-meltblown-spunbond (SMS) material. In other embodiments, the nonwoven material may be a porous nonwoven material, such as TABCW or a chemically bonded nonwoven material, or the like. In some specific embodiments, the reinforcement material 116 may consist essentially of polyolefin bicomponent fibers, or a mixture of polyolefin bicomponent and eccentric fibers, or only polyolefin eccentric fibers. However, it should be understood that these are only some exemplary materials. Other suitable materials may be used in other contemplated embodiments. In other embodiments, the basis weight of the reinforcement material 116 may preferably be between about 30 gsm and about 60 gsm, or between about 35 gsm and about 55 gsm, or between about 40 gsm and about 50 gsm.

Core wrap material 120 may be at least partially wrapped around top cover material 103 , reinforcement material 116 , and bottom cover material 101 . As shown in Figure 3, core wrap material 120 may be partially wrapped around materials 101, 103 and reinforcement material 116, leaving a gap between the ends of core wrap material 120, sometimes referred to as a "C-fold" configuration. Although the gap between the ends of the core wrap material 120 is shown adjacent the bottom cover material 101 , in other embodiments the gap may be located adjacent the top cover material 103 . However, in other embodiments, core wrap material 120 may be completely wrapped around materials 101 , 103 and reinforcement material 116 such that materials 101 , 103 and reinforcement material 116 are completely enveloped by core wrap material 120 .

The core wrap material 120 may be bonded to one of the materials 101 , 103 via adhesive seam beads 106 . Such adhesive beads 106 may extend along the length dimension of the absorbent body 54 and be disposed adjacent the ends of the core wrap material 120 . However, in other embodiments, different adhesive configurations may be used to bond core wrap material 120 to materials 101, 103 and/or reinforcement material 116. For example, instead of just the adhesive bead 106 , the adhesive may cover a majority of the side of the core wrap material 120 facing the materials 101 , 103 and reinforcement material 116 such that the core wrap material 120 is bonded all the way around the structure to the material 101 , 103 and reinforcement materials 116. In yet other embodiments, additional beads of adhesive may be used so that the core wrap material 120 bonds to both materials 101, 103. In general, core wrap material 120 may be bonded to materials 101, 103 and/or reinforcement material 116 in any suitable manner.

The core wrapping material 120 may be made of tissue materials, spunbond and/or meltblown materials (eg, spunbond-meltblown materials and spunbond-meltblown-spunbond materials), spunlace materials, Materials, which are commercially available from Kimberly-Clark World, Inc., airlaid materials, airlaid materials and through-air bonded carded webs (TABCW) and coform materials. The core wrap material 120 may have a basis weight between about 8 gsm and about 35 gsm. However, it should be understood that these are only exemplary materials and basis weights. In general, any suitable material of any suitable basis weight may be used.

As mentioned previously, in some embodiments, core wrap material 120 is optional. In some of these alternative embodiments, the top cover material 103 may be bonded directly to the bottom cover material 101 , such as by adhesive seam beads 106 , thereby encapsulating the reinforcement material without the use of core wrap material 120 116. However, it should be understood that in these embodiments, other adhesive configurations may be used to bond the materials 101, 103 together.

In at least some of these embodiments that do not include core wrap material 120 , top cover material 103 may be wrapped around reinforcement material 116 to bond with bottom cover material 101 . In other embodiments, both bottom cover material 101 and top cover material 103 may be partially wrapped around reinforcement material 116 , or bottom cover material 101 may be wrapped around a majority of reinforcement material 116 to bond with top cover material 103 . Bottom cover material 101 or top cover material 103 may be wrapped around reinforcement material 116 and at least a portion of the other of bottom cover material 101 and top cover material 103 such that at least a portion of the other of bottom cover material 101 and top cover material 103 Part of it is enclosed. In such a configuration, the wrapped material 101 or 103 may form a C-shaped fold, or may completely enclose the other of the materials 101, 103. In still other embodiments, body 54 may include only a single covering material 101 or 103. In such embodiments, a single cover material 101 or 103 may be wrapped around reinforcement material 116 and bonded to itself to completely encapsulate reinforcement material 116 .

The absorbent body 54 may also contain absorbent materials to provide the absorbent body 54 with beneficial fluid intake and storage (eg, fluid retention) qualities. For example, absorbent body 54 may include SAM disposed throughout body 54, as depicted by SAM particles 115 in Figures 3, 7, 8, and 10. In some embodiments, the absorbent material of body 54 may comprise an absorbent material consisting essentially of SAM only, or in other embodiments, may comprise both SAM and fibrous absorbent material (such as pulp fluff). In this disclosure, the phrase "substantially only" means that qualifying materials may comprise greater than or equal to 90% of the total weight of the described materials of the absorbent body 54. For example, where the absorbent body 54 includes absorbent material that includes substantially only SAM, the body 54 then includes an amount of SAM that weighs greater than or equal to 90% of the total weight of all absorbent materials of the body 54 .

To maintain the absorbent body 54 in a cohesive structure and to help stabilize the absorbent material within the body 54, the body 54 may also include an adhesive. Generally speaking, adhesives may be applied to different materials of body 54 to form different adhesive layers, such as adhesive layers 105, 109. Adhesive layer 105 may be applied to bottom cover material 101 and/or reinforcement material 116 to laminate bottom cover material 101 to reinforcement material 116 . Likewise, an adhesive layer 109 may be applied to the top cover material 103 and/or the reinforcement material 116 to laminate the top cover material 103 to the reinforcement material 116 .

Figure 4 is a schematic diagram of a method 200 of making the absorbent body 54 of the present disclosure. In a first step, the first covering material 201 having a top side and a bottom side may be unwound from a reel including the material from which the first covering material 201 is formed. The first cover material 201 may correspond to the top cover material 103 previously described with respect to the absorbent body 54 of the present disclosure. However, in other embodiments, the first cover material 201 may correspond to the bottom cover material 101 previously described. The first adhesive 209 may be applied to the top side of the first cover material 201 by the adhesive application device 210 to form a first adhesive layer on the first cover material 201 . The adhesive 209 forming the first adhesive layer may correspond to the previously described adhesive layer 109 . However, in other embodiments, the adhesive 209 forming the first adhesive layer may correspond to the adhesive layer 105 previously described.

As shown, reinforcement material 202 having top and bottom sides may also be unrolled from the spool and may be further coupled to first cover material 201 with adhesive 209 sandwiching the top side of first cover material 201 with the reinforcement material between the bottom sides of 202. Reinforcement material 202 may correspond to reinforcement material 116 described above. Although shown in FIG. 4 as being applied to the top side of the first cover material 201 , in alternative embodiments, the adhesive 209 may be applied to the underside of the reinforcing material 202 . Thus, adhesive 209 is operable to laminate the top side of first cover material 201 directly to the underside of reinforcement material 202 . As used herein, the descriptor "direct" means that two materials are bonded together without an intervening material other than a bonding material such as an adhesive. Therefore, the top side of first cover material 201 can be considered to be directly bonded to the bottom side of reinforcement material 116 via adhesive 209 .

Adhesive 209 may be applied at an addition rate of between about 0.5 gsm and about 10 gsm. In other preferred embodiments, adhesive 209 may be applied at an addition rate of between about 1 gsm and about 5 gsm. Adhesive 209 may be applied according to any conventional adhesive application method (such as blowing, spraying, slot coating, etc.). Additionally, any suitable pattern may be used, including swirl patterns, bead patterns, lines, etc.

Next, the combined first covering material 201 and reinforcing material 202 are transported to the conveyor 240 . While first cover material 201 and reinforcement material 202 are disposed above conveyor 240, SAM, such as SAM particles 115 shown in Figure 3, may be dispensed onto reinforcement material 202. For example, SAM may be stored in hopper 215 and dispensed to reinforcement material 202 via conduit 216 . In some embodiments, hopper 215 and conduit 216 may represent a gravity feed system whereby SAM is dispensed from conduit 216 by gravity.

The SAM is dispensed from conduit 216 in a metered manner such that a specified amount of SAM is deposited on reinforcement material 202 . The SAM can be dispensed in this manner to achieve an addition rate of between about 90 gsm and about 350 gsm. When the SAM contacts reinforcement material 202 , at least some of the SAM may penetrate into reinforcement material 202 . For example, the properties of the reinforcement material 202 may be such that the voids between the fibers of the reinforcement material 202 are larger than at least some individual particles of the dispensed SAM, such that at least some particles of the dispensed SAM may filter into the interior of the reinforcement material 202 due at least to gravity.

In some embodiments, conveyor 240 may be a vacuum conveyor through which air is drawn through first cover material 201 and reinforcement material 202 and into vacuum conveyor 240 . In additional or alternative embodiments, the conveyor 240 may vibrate to vibrate the first cover material 201 and reinforcement material 202 as the SAM is dispensed from the hopper 215 . This addition of vacuum or vibration energy to the first cover material 201 and reinforcement material 202 may help increase penetration of the dispensed SAM throughout the reinforcement material 202 . However, in embodiments disclosed herein, the use of vacuum and/or vibrational energy is not required to achieve the amount of SAM stabilized within reinforcement material 202 . However, in at least some embodiments, transmitter 240 is not necessary for the SAM allocation process.

Next, the second cover material 203 may be unrolled from the spool and brought to cover the portion of the core assembly 211 including the first cover material 201, reinforcement material 202, and the applied SAM. In some embodiments, the second cover material 203 may be guided by guide rollers 204 . The second cover material 203 may correspond to the bottom cover material 101 in some embodiments, or the top cover material 103 in other embodiments.

Before bringing the second cover material 203 to the partial core assembly 211 , adhesive 205 may be applied to the underside of the second cover material 203 by the adhesive application device 212 . This second adhesive 205 may form an adhesive layer that may correspond to adhesive layer 105 . However, in other embodiments, adhesive 205 may form an adhesive layer that may correspond to adhesive layer 109 . It can be seen that the second adhesive 205 is applied to the bottom side of the second cover material 203 such that the second adhesive 205 is disposed between the bottom side of the second cover material 203 and the partial core assembly 211 and the second adhesive 205 is The underside of the second covering material 203 is bonded directly to the partial core assembly 211 . In practice, this results in a direct bond between the underside of the second cover material 203 and the top side of the reinforcing material 202 . However, in other embodiments, the second adhesive 205 may be applied directly to the partial core assembly 211 before the second cover material 203 is applied to the partial core assembly 211 . For example, the second adhesive 205 may be applied directly to the top side of the reinforcement material 202 and the applied SAM deposited on the reinforcement material 202 .

Adhesive 205 may be applied at an addition rate of between about 0.5 gsm and about 10 gsm. In other preferred embodiments, adhesive 205 may be applied at an addition rate of between about 1 gsm and about 5 gsm. Adhesive 205 may be applied according to any conventional adhesive application method (such as blowing, spraying, slot coating, etc.). Additionally, any suitable pattern may be used, including swirl patterns, bead patterns, lines, etc.

The core assembly 213 including the first cover material 201, reinforcement material 202, SAM and second cover material 203 (together with adhesives 209 and 205) may then be further processed. For example, core assembly 213 may be transferred via conveyor 244 to another processing station. In some embodiments, core assembly 213 may pass through the nip, thereby applying pressure and/or heat to core assembly 213 . Additionally or alternatively, the core assembly 213 may be passed through a bonding station to seal the side edges of the core assembly 213 . In yet other embodiments, the core assembly may be transferred to a core wrapping station with core wrapping material (such as core wrapping material 120 ) at least partially wrapped around core assembly 213 . As shown in Figure 3, at least some of these embodiments may result in the formation of adhesive beads 106.

The core assembly 213 may be further incorporated into an absorbent garment or absorbent article precursor product. For example, process 200 may be a sub-process of an absorbent garment forming process that results in a finished absorbent garment product, such as article 20 shown in FIGS. 1 and 2 . In such cases, the core assembly 213 may be cut into individual absorbent bodies 54 for incorporation into an absorbent garment or garment precursor product. Many such processes are well known in the art. In additional embodiments, after core assembly 213 has been formed, core assembly 213 may be rolled. Such rolls of core assembly 213 may then be conveyed for use in a separate absorbent garment manufacturing process.

In at least some embodiments, core assembly 213 may be inverted prior to application to an absorbent garment or absorbent garment precursor product. For example, at least some of the embodiments of the process 200 as described in connection with FIG. 4 produce the absorbent body 54 by constructing the absorbent body 54 in an "upside-down" manner. That is, in some embodiments, the first cover material 201 disposed on the bottom throughout process 200 becomes the top cover material 103 of the absorbent body 54 when the body 54 is turned over. This "flipped" structure can correspondingly be seen in Figure 3, where the underside of the top covering material 103 is directly bonded to the top side of the reinforcing material 116 via an adhesive layer 109, and where the underside of the reinforcing material 116 is directly bonded to the top side of the reinforcing material 116. Bonded to the top side of the bottom covering material 101.

When the absorbent body 54 is constructed in this manner, the SAM is applied to the portion that becomes the bottom side (eg, the garment-facing side) of the reinforcement material 202 when the body 54 is placed into the product. In these embodiments, most of the SAM applied to reinforcement material 202 remains at or near the interface between second cover material 203 and reinforcement material 202 , while some SAM penetrates into reinforcement material 202 .

When the first cover material 201 is positioned in an absorbent article as the top cover material 103 (eg, the portion of the absorbent body 54 closest to the body-facing surface of the article), the absorbent body 54 exhibits benefits over other absorbent bodies. performance. Because the SAM has been applied to what becomes the underside of the reinforcement material 116 , and because most of the SAM does not penetrate the reinforcement material 116 to migrate to the top cover material 103 , a relatively small amount of SAM is located near the top cover material 103 . This structure provides beneficial properties of the absorbent body 54 as it relates to inhalation speed and dryness, as will be described in greater detail below.

Using the process described above, it has been found that control of the desired amount of SAM within different locations of the stable absorbent body 54 can be achieved. In particular, it has been found that ensuring that greater than about 30% and less than about 85% of the total amount of SAM particles 115 within the body 54 is stabilized within the reinforcement material 116 (according to the SAM Stable Position Test Method) results in beneficial properties of the absorbent body 54 . In other preferred embodiments, the amount of SAM particles 115 stabilized within the reinforcement material 116 may range from about 40% to about 75% of the total amount of SAM particles 115 within the body 54 .

As used herein, the term "stable" means retained. For example, when SAM particles 115 contact adhesive layer 105, SAM particles 115 will stick to adhesive layer 105 and be retained. Due to the porosity of the reinforcement material 116, at least some of the SAM particles 115 are able to penetrate into the interior of the reinforcement material 116. These SAM particles 115 may filter through the pores in the reinforcement material 116 and end up sticking somewhere within the reinforcement material 116 - for example due to the size and/or shape and/or orientation of the fibers 117 and pores within the reinforcement material 116 and the SAM particles 115 in size and shape. Therefore, these "adhered" SAM particles 115 remain within the reinforcement material 116 and are considered to be stable within the reinforcement material 116 . Determination of how much SAM is stable within different portions of the absorbent body 54 may be determined by the SAM Stability Position Test Method described herein.

Gel plugging has been found to occur within reinforcement material 116 if the amount of SAM particles 115 stabilized within reinforcement material 116 is greater than approximately 85% of the total amount of SAM particles 115 within body 54 . Gel blocking occurs due to expansion of SAM particles 115 (due to fluid absorption) preventing fluid in and through the reinforcement material 116 from entering other SAM particles 115 . The expansion may lengthen the fluid flow path within the reinforcement material 116 , thereby improving the liquid uptake rate, rewet performance, and even retained capacity of the body 54 compared to other bodies 54 that stabilize lower amounts of SAM particles 115 within the reinforcement material 116 Have a negative impact (e.g. increase). Comparative results from three soaked liquid inhalation tests show that the absorbent body according to absorbent body 54 (in which 40% of the total amount of SAM particles 115 is stabilized within the reinforcement material 116) is better than the absorbent body according to absorbent body 54 (in which the SAM particles 115 85% of the total amount stabilized within the reinforcement 116) performs approximately 12% better.

Therefore, it is hypothesized that by stabilizing a larger proportion of SAM particles 115 (such as greater than about 85%) within the reinforcement material 116 , such particles 115 expand and block the path for liquid penetration into the reinforcement material 116 , thereby increasing the inhalation velocity to no more than level of expectations. In other embodiments, it may be preferable to stabilize no more than about 70% of the total amount of SAM particles 115 within the body 54 within the reinforcement material 116 in order to produce the desired liquid intake velocity.

On the other hand, it has been found that if the amount of SAM particles 115 stabilized within the reinforcement material 116 is less than about 30% of the total amount of SAM particles 115 within the body 54 , the laminate strength between the reinforcement material 116 and the bottom cover material 101 may be negatively affected. For example, with such a low percentage of SAM particles 115 stabilized within the reinforcement material 116 , a correspondingly large number of SAM particles 115 are stabilized at the adhesive layer 105 . A large amount of SAM particles 115 bonded to the adhesive layer 105 does not leave a large amount of open tack of the adhesive layer 105 as in other embodiments where a smaller amount of SAM particles 115 is stabilized at the adhesive layer 105 . The mixture is used to bond the reinforcing material 116. Lower bond strength between the reinforcement material 116 and the bottom cover material 101 may result in lower pad integrity, which may affect the performance of the body 54 and user comfort.

With such a low percentage of SAM particles 115 stabilized within the reinforcement material 116, it was also found that SAM "islands" can form on the adhesive layer 105. Such SAM "islands" may be the result of too many SAM particles 115 being present to bond to the adhesive layer 105 . As a result, SAM particles 115 may migrate at the interface between the reinforcement material 116 and the bottom cover material 101, ultimately forming clumps or "islands." These SAM "islands" can negatively impact the fluid intake and retention capacity of the body 54 and cause uncomfortable lumps within the body 54 .

Therefore, due to the above-described issues, it is preferred that greater than about 30% and less than about 85% of the total amount of SAM particles 115 within body 54 are stabilized within reinforcement material 116 . This range is particularly useful when the amount of SAM particles 115 within the absorbent body is between about 90 gsm and about 350 gsm. Other preferred embodiments may have greater than about 40% and less than about 75% of the total amount of SAM particles 115 stabilized within the body 54 within the reinforcement material 116 (as determined by the SAM Stable Position Test Method), wherein the absorbent within the body The total amount of SAM particles 115 is between about 90 gsm and about 350 gsm.

In some specific embodiments, at least some of the SAM particles 115 may be filtered through the reinforcement material 202 during the process 200 . These SAM particles 115 are then stabilized by an adhesive 209, which corresponds to the adhesive layer 109 as shown in Figure 3. However, the SAM particles 115 stabilized in this manner typically comprise only a small fraction of the SAM particle 115 content of the absorbent body 54 produced by the process 200 . Generally speaking, it is desirable that the amount of SAM particles 115 stabilized by the adhesive layer 109 is relatively low to ensure that the desired liquid uptake rate through the absorbent body 54 is achieved. Expansion of SAM particles 115 stabilized by adhesive layer 109 will generally lengthen the fluid flow path into and through body 54 and therefore relative to an absorbent body having a lower percentage of SAM particles 115 stabilized at adhesive layer 109 54 typically results in longer liquid intake times for the body 54.

It has been found that a useful range of amounts of SAM particles 115 stabilized by the adhesive layer 109 still results in an acceptable liquid uptake rate (time) of less than about 10% by weight of the total weight of the SAM particles 115 in the absorbent body 54, as determined by Determined by the SAM stable position test method. In other embodiments, it may be preferred to have less than about 7.5%, or less than about 5%, or less than about 2.5%, or less than about 1%, or less than about 0.5% of the total amount of SAM particles 115 of the absorbent body 54 Stable at adhesive layer 109, as determined according to the SAM Stable Position Test Method.

It has also been found that these specific stabilization percentages are useful where the reinforcement material 116 has specific properties. For example, where the reinforcement material 116 is between about 25 gsm and about 80 gsm and the SAM particles 115 are disposed within the absorbent body 54 in an amount between about 90 gsm and about 350 gsm, the absorbent body 54 can be adjusted to the inhalation speed and Aspects related to drying performance performed well. In other preferred embodiments, the reinforcement material 116 may be between 35 gsm and about 70 gsm, or between about 40 gsm and about 65 gsm, and wherein the SAM particles 115 are disposed in an amount between about 90 gsm and about 350 gsm. inside the absorption body 54.

A thickness of reinforcement 116 between about 0.8 mm and about 3.0 mm may be additionally beneficial in accordance with the post-cut reinforcement height test method detailed below. In other preferred embodiments, the reinforcement material 116 may have a thickness of between about 1.0 mm and about 2.5 mm according to the Cut Reinforcement Material Height Test Method. This combination of basis weight and thickness allows the reinforcement material 116 to be sufficiently porous to allow for the desired SAM stabilization percentages detailed herein. For example, these ranges create a porosity of the reinforcement material 116 that allows SAM particles 115 to penetrate into the reinforcement material 116 while providing a sufficient volume of reinforcement material 116 for the SAM particles 115 to penetrate to produce the desired stabilization percentage.

If the reinforcement 116 has a height greater than about 3.0 mm (according to the cut reinforcement height test method) and has a basis weight between about 25 gsm and about 80 gsm (depending on the particular material type of the reinforcement 116 ), the interfiber The spacing may make it impossible to stabilize the desired amount of SAM particles 115 within the reinforcement material 116 due to the relatively large pores within the reinforcement material 116 due to the large height and low basis weight. In other embodiments, it may not be possible to stabilize the desired amount of SAM particles 115 within the reinforcement 116 having a height greater than about 2.5 mm (according to the Post-Cut Reinforcement Height Test Method) while having a height between about 20 gsm and Basis weight between 60gsm (depending on the specific material type of reinforcement 116).

Conversely, where the reinforcement material 116 has a height of less than about 0.8 mm or about 1.0 mm (at any suitable basis weight, such as between about 15 gsm and about 150 gsm), the reinforcement material 116 may not have a sufficient thickness. to maintain and stabilize the desired amount of SAM particles 115 within the reinforcement material 116 . In such instances, a smaller amount of SAM particles 115 stabilized within the reinforcement material 116 leaves a relatively larger amount of SAM particles 115 at the interface between the reinforcement material 116 and the bottom cover layer 101 , which may result as described above. The SAM islands and/or laminate strength issues. In determining these issues with high and low reinforcement material 116 heights having the stated basis weights, it should be understood that these issues are found when using the amount of SAM particles 115 required to achieve a presence between about 90 gsm and about 350 gsm. , which generally represents the useful amount of SAM particles in the absorbent article.

Referring back to process 200 of Figure 4, it is described that additional processing steps may be performed once core assembly 213 has been formed. An optional additional processing step not previously described is the embossing of the core assembly 213 . FIG. 5 depicts an exemplary embossing process 300 that may be used to emboss core assembly 213 . It should be understood that although process 300 may impart beneficial properties to core assembly 213 (and therefore absorbent body 54 formed from core assembly 213), this embossing process is a purely optional step in the process for forming absorbent body 54.

As can be seen in Figure 5, the core assembly 213 can be advanced to the embossing rollers 302, 304 forming a nip. In at least some embodiments, core assembly 213 may be advanced to embossing rollers 302 , 304 with second cover material 203 oriented upwardly to contact embossing roller 302 and first cover material 201 oriented downwardly to contact embossing roller 304 . The embossing rollers 302, 304 operate to emboss the core assembly 213 as the core assembly 213 is advanced between the embossing rollers 302, 304. Preferably, embossing roller 302 includes embossing elements 342 pressed into core assembly 213 . In the above orientation, the embossing elements 342 may be pressed into the second cover material 203 as the core assembly 213 is advanced between the embossing rollers 302, 304. Generally speaking, it may be most advantageous to emboss the side of the core assembly 213 on which the SAM particles 115 are applied.

It has been found that embossing the core assembly 213 by pressing one or more embossing elements 342 into the second cover material 203 can help increase the amount of SAM particles 115 stabilized within the reinforcement material 116 of the core assembly 213 . Accordingly, embossing the core assembly 213 , and particularly the second cover material 203 of the core assembly 213 , may help achieve a desired percentage of SAM particles 115 stabilized within the reinforcement material 116 . Of course, individual absorbent bodies 54 may be formed from the core assembly 213 prior to embossing the core assembly 213, and these individual absorbent bodies 54 may be individually embossed and achieve the benefits detailed herein.

6A and 6B depict a top plan view and a side plan view, respectively, of a portion of face 340 of embossing roll 302 (shown in a lay-flat configuration). As can be seen, face 340 of embossing roller 302 may include a plurality of embossed elements 342 having embossed surfaces 344 . In at least some embodiments, embossing roller 304 may be a smooth roller. In some embodiments, rollers 302 and/or 304 may be heated, but this is not required in all embodiments.

Generally speaking, embossed elements 342 may be of any suitable size and shape. In at least some embodiments, embossed elements 342 are conical in shape with a flat embossed surface 344 (as shown in Figure 6B). In other embodiments, embossed elements 342 may be cylindrical and/or have circular embossed surfaces 344. In additional embodiments, embossed elements 342 and/or embossed surfaces 344 themselves may have an oval shape, or a rectangular shape, or a star shape, or any other suitable shape. In yet other embodiments, the embossed elements 342 may form embossed strips extending transversely, longitudinally, or diagonally across the face 340 of the roller 302.

The embossed elements 342 may have a longitudinal spacing 346 and a transverse spacing 348 between adjacent embossed elements 342 . The embossed surfaces 344 of adjacent embossed elements 342 may have a longitudinal spacing 352 and a transverse spacing 354 (as measured from the center of the embossed surface 344). In some embodiments, the lateral spacing 346 and/or the longitudinal spacing 348 may be zero such that the bases of the embossed elements 342 abut each other longitudinally and/or transversely while being tapered by the embossed elements 342 throughout their height 350 A lateral spacing and/or a longitudinal spacing between the embossed surfaces 344 of such embossed elements 342 is achieved, as shown in Figure 6B.

The embossed elements 342 may generally be configured to impart an embossed area to the core assembly 213 (or individual absorbent body 54) embossed by the process 300. During process 300, core assembly 213 or separate absorbent body 54 may have a surface facing embossed elements 342 that becomes embossed. For example, in some of the previously described embodiments, during process 300 , the top surface of second cover material 203 may be the surface facing core assembly 213 of embossed element 342 . During process 300, the surface of core component 213 or individual absorbent body 54 facing embossed element 342 has a region, which may be referred to herein as the core component region or absorbent body region.

The embossed areas of the core assembly 213 or individual absorbent body 54 may be considered those portions of the surface of the core assembly 213 or individual absorbent body 54 that are indented as a result of the embossing process 300 . The areas of these recessed portions can be added together and divided by the area of the core assembly or absorbent body to obtain the embossed area percentage. As a simple example, if the core assembly 213 or individual absorbent body 54 has an area of 100 mm2, and that core assembly or absorbent body area has been embossed by ten embossing elements 342 to produce an area of 1 mm2 each area of indentation, then the embossed area percentage of core assembly 213 or absorbent body 54 alone would be considered 10% (e.g., 10 mm2 of embossed surface 344 divided by 100 of core assembly 213 or absorbent body 54 alone area in square millimeters).

In one experiment, a series of absorbent bodies 54 were fabricated according to process 200 . The first of these formed absorbent bodies 54 remained unembossed, and it was determined to have approximately 37.2% of the SAM particles 115 stabilized within its reinforcement material 116 within this first absorbent body 54 . The second of these formed absorbent bodies 54 is embossed, such as by the process of process 300, to have an embossed area percentage of 8%. The second absorbent body 54 was determined to have approximately 40.5% of the SAM particles 115 stabilized within its reinforcement material 116 within the second absorbent body 54 . The third of these formed absorbent bodies 54 is embossed, such as by the process of process 300, to have an embossed area percentage of 12%. The third absorbent body 54 was determined to have approximately 48.9% of the SAM particles 115 stabilized within its reinforcement material 116 within the third absorbent body 54 .

Accordingly, experiments have shown that embossing such core components 213 in the manner described in conjunction with process 300 allows for embedding within the reinforcement material 116 of the core components 213 (and, therefore, the absorbent body 54 formed from such embossed core components 213). The amount of SAM particles 115 increases by approximately 0.98% to approximately 1.06% of the embossed area. Accordingly, it may be beneficial to emboss the core assembly 213 of the present disclosure to achieve an embossed area percentage of the assembly 213 between greater than about 0% and about 42%. This range of embossing area may achieve sufficient penetration of the SAM particles 115 into the reinforcement material 116 to allow the formation of the absorbent body 54 having the previously disclosed percentage of SAM particles 115 stabilized within the reinforcement material 116 .

Other preferred ranges of embossed area percentage for core assembly 213 of the present disclosure may be between about 5% and about 35%, or between about 10% and about 30%, or between about 10% and about 25%. %, or between about 10% and about 20%. These smaller ranges may be more broadly useful in achieving a desired percentage of stable SAM particles 115 within the reinforcement material 116 of the core assembly 213 of the present disclosure. For example, compared to an embossing device configured to achieve an embossing area percentage of between about 0% to 10% or about 20% to 42%, using an embossing device configured to achieve an embossing area percentage of between about 10% and about 20% An embossing apparatus (e.g., including at least embossing rollers 302, 304) having an embossing area percentage of core assembly 213 is effective in producing a desired percentage of SAM particles 115 stabilized within reinforcement material 116 of core assembly 213 (e.g., medial may be more efficient with respect to core components 213 having a wider range of differences (eg, reinforcement type, basis weight and thickness, SAM additions, etc.) between about 30% and about 85%). This disclosure should not be construed as limiting the useful range of the disclosed embossed area percentages of about 0% and about 42%, but rather is to be construed as understanding that when changing the characteristics of the core assembly 213 (such as the composition of the reinforcement material 116, basis weight or height, or the amount of SAM particles 115 added within the core assembly 213), there is the benefit of using an embossing assembly that is configured to achieve an embossing area percentage between about 10% and 20% - such that no The embossing equipment is changed or adjusted (to achieve different embossing area percentages to ensure that the desired percentage of SAM particles 115 is stabilized within the reinforcement material 116).

Referring back to embossing pin height 350, embossing pin height 350 when used in accordance with the structures (eg, core assembly 213 and absorbent body 54) and materials (reinforcement material 116, cover materials 101, 103, 201, 203) disclosed herein Typically this can vary between about 0.5mm and about 4.0mm. In general, it may be preferable that the combination of pin height 350 and nip spacing between rollers 302, 304 does not produce too great an embossing depth. The embossing depth may be considered the distance that the element 342 penetrates into the core assembly 213 or the absorbent body 54 alone. If the combination of pin height 350 and nip spacing creates too great an embossing depth, the SAM particles 115 may be pushed through the reinforcement material 116 all the way to the first cover material 201 (or top cover material 103 ) and, for example, through the adhesive 210 /109 stabilizes at the first covering material (or the top covering material). Accordingly, this may reduce the percentage of SAM particles 115 stabilized within the reinforcement material 116 below a desired level and/or increase the percentage of SAM particles 115 stabilized at the material 201/103 to undesirable levels.

It has been found that it may be preferable for the embossing depth to be less than about 90% of the thickness of the core assembly 213 or the absorbent body 54 alone. In other embodiments, it may be preferred that the embossing depth is less than about 85%, or less than about 80%, or less than about 75%, or less than about 70% of the thickness of the core assembly 213 or individual absorbent body 54 . On the other hand, if the embossing depth is not deep enough, the effectiveness of increasing the percentage of SAM particles 115 stabilized within the reinforcement material 116 will be reduced. Therefore, it may be preferred that the embossing depth is greater than about 25% of the thickness of the core assembly 213 or absorbent body 54 alone. In other preferred embodiments, it may be preferred that the embossing depth is greater than about 30%, or greater than about 35%, or greater than about 40%, or greater than about 45%, of the thickness of the core assembly 213 or the individual absorbent body 54. or greater than about 50%.

As described above with respect to FIG. 5 , process 300 is shown as being performed on core assembly 213. However, in other embodiments, process 300 may be performed on a portion of core assembly 211. For example, during process 200, after SAM particles have been dispensed onto reinforcement material 116 (e.g., from hopper 215 and through conduit 216), a portion of core assembly 211 including first cover material 201, reinforcement material 202, and dispensed SAM particles (and possibly adhesive 209) may be advanced through process 300. In such embodiments, embossing element 342 may emboss reinforcement material 202 by directly contacting reinforcement material 202. In contrast, with respect to process 300 depicted in FIG. 5 , embossing element 342 may directly contact second cover material 203 and emboss second cover material 203 and reinforcement material 202 simultaneously, e.g., because the embossing depth causes embossing element 342 to penetrate into reinforcement material 202 at least to some extent.

In addition to increasing the amount of SAM particles 115 stabilized within the reinforcement material 116 of the assembly 113 or body 54, another effect of embossing the core assembly 213 (and/or the absorbent body 54) of the present disclosure is that the embossing of the SAM particles At least some of 115 are positioned within reinforcement material 116 . This feature can be seen more clearly with respect to Figures 7 and 8, which are photographs of reinforcement material 116 removed from different absorbent bodies 54. The reinforcement material 116 shown in the photograph of Figure 7 was taken from the unembossed absorbent body 54, while the reinforcement material 116 shown in the photograph of Figure 8 was taken from the embossed absorbent body 54.

Figures 7 and 8, which depict different reinforcement materials 116, show individual SAM particles 115 and individual fibers 117 in each of the reinforcement materials 116 of Figures 7 and 8. It can be seen that the SAM particles 115 of the reinforcement material 116 of Figure 7 are more or less randomly distributed within the reinforcement material 116, resulting in a relatively uniform distribution of SAM particles 115 throughout the reinforcement material 116. No area within the reinforcement material 116 of FIG. 7 has a significantly higher concentration of SAM particles 115 than other areas of the reinforcement material 116 . Alternatively, to the extent that the SAM particle 115 concentration differs on a microscale, such differences are randomly oriented throughout the reinforcement material 116 of FIG. 7 .

In contrast, it can be seen that the reinforcement material 116 of Figure 8 has regions 275 of high SAM particle concentration and regions 276 of low SAM particle concentration. These regions 275, 276 of high SAM particle concentration and low SAM particle concentration are formed according to patterns. That is, these regions 275, 276 of high SAM particle concentration and low SAM particle concentration do not occur randomly. Instead, these regions of high SAM particle concentration and low SAM particle concentration 275, 276 are oriented in a regular repeating sequence. In the specific example of FIG. 8 , zone 275 is surrounded by zone 276 . However, it should be understood that other patterns may be formed. For example, regions 275 may form longitudinally or laterally extending, alternating strips or bands, with regions 276 oriented on either side of a single region 275 . In yet other embodiments, regions 275 may be offset (longitudinal and/or transversely) relative to adjacent regions 275 rather than aligned as shown in FIG. 8 . Generally speaking, such pattern of locations of regions 275 may substantially correspond to the embossing pattern used to emboss the core assembly 213 or the absorbent body 54 . Thus, the location of zone 275 may correspond to the embossed area of reinforcement material 116 .

Embossing the core assembly 213 and/or absorbent body 54 of the present disclosure to achieve such patterned areas of high SAM particle concentration and low SAM particle concentration may provide increased stabilization of SAM particles 115 within the reinforcement material 116 over and above those previously described. The amount of embossing benefits benefits. By creating regions of high and low SAM concentration 275 , 276 , fluid flows through the reinforcement material 116 more easily than when the SAM is more evenly distributed throughout the reinforcement material 116 . For example, in the embodiment of Figure 7 where the SAM particles 115 are more evenly distributed throughout the reinforcement material 116, as the fluid flows and penetrates through the reinforcement material 116, the SAM particles 115 stabilized within the reinforcement material 116 will begin to absorb the fluid. and expand. This expansion may close the path for fluid flow, thereby increasing the length of the path that fluid can travel all the way through reinforcement material 116 . However, in the embodiment of FIG. 8 , as the SAM particles 115 expand, the low SAM concentration regions 276 may remain relatively open and unobstructed to better allow fluid to continue flowing all the way through the reinforcement material 116 . This may result in the absorbent body 54 performing better in terms of inhalation performance than the unembossed body 54.

Accordingly, it may be useful to emboss the absorbent body 54 (other than those disclosed only with respect to FIG. 3) relative to other absorbent body structures in the manner described herein. Figure 9 is a schematic diagram of an exemplary manufacturing process 200' for producing other absorbent bodies that may be embossed according to process 300 to achieve at least some of the benefits described herein. Process 200' is similar to process 200, except that process 200' has two separate SAM dispensing steps. In process 200', SAM particles (such as SAM particles 115) may be dispensed directly onto first cover material 201 (or to adhesive 209 disposed on first cover material 201, for example) from SAM hopper 215a and through conduit 216a superior). After the SAM particles have been dispensed onto the first cover material 201 , as in process 200 , the reinforcement material 202 can be bonded together with the first cover material 201 . Next, additional SAM particles may be dispensed onto reinforcement material 202 in a manner similar to that described above with respect to process 200, such as from SAM hopper 215b and through conduit 216b. The remaining steps of process 200' are similar to those described in connection with process 200, such as combining second cover material 203 with portions of core assembly 211 to form core assembly 213.

The resulting core assembly 213 of process 200' may then have a much higher percentage of SAM particles 115 stabilized at the first cover material 201 than that described in conjunction with the core assembly 213 produced by process 200 (in the core of process 200' total amount of SAM particles 115 in assembly 213). The core components 213 produced by process 200' may be processed in any manner similar to that described with respect to the core components 213 produced by process 200, such as by separation into separate absorbent bodies and placement in an absorbent garment or garment precursor product. , as shown in Figures 1 and 2. In at least some embodiments, this additional processing may include embossing the core components 213 manufactured by process 200' in accordance with process 300 described herein.

Figure 10 depicts an exemplary cross-section viewed along line 3-3 of Figure 2, wherein absorbent body 54 of Figure 2 is the absorbent body formed by process 200'. The absorbent body of Figure 10 is labeled absorbent body 54'. It can be seen that there are many more SAM particles 115 stabilized at the top cover material 103 than shown in the absorbent body 54 . The absorbent body 54' may sometimes be referred to in the art as a 5-layer complex absorbent body (or core).

Such absorbent bodies 54' may also benefit from the embossing process 300 described in connection with Figure 5, like the absorbent body 54 described in connection with Figure 3. For example, embossing the core assembly 213 formed by process 200' (or directly on a separate absorbent body 54') may help further distribute the SAM particles 115 from the base cover material 203 to stabilize within the reinforcement material 116. Additionally, embossing can help position the SAM particles 115 within the reinforcement material 116 of the absorbent body 54' to help create zones of low SAM concentration, thereby allowing better fluid flow and penetration through the reinforcement material 116 of the absorbent body 54'. .

SAM stable position test method:

To determine the amount of SAM particles 115 stabilized in different portions of the absorbent body (such as absorbent body 54), the following steps may be performed.

First, a table can be developed detailing the basis weights of the different materials that comprise the absorbent body. These basis weights may be determined from the absorbent body product specifications used to form such absorbent bodies or may be determined from various known analytical techniques.

Table 1 lists on the left side of Table 1 exemplary components of an absorbent body according to the absorbent body 54 described herein. The basis weights of the various components in the absorbent body are listed in the second column. Adding the basis weights of each of the absorbent bulk components gives the total basis weight value listed at the bottom of the second column. Next, the ratio of each absorbent body component can be calculated and recorded (in the third column), comparing the basis weight of each component to the total basis weight value.

Basis weight(gsm) Proportion Total weight(g) Bottom core wrap material (e.g., Material 101) 50 13.2% 4.62 Bottom adhesive layer (e.g., adhesive layer 105) 5 1.3% 0.455 SAM 240 63.5% 22.2 Reinforcement materials (e.g., Material 116) 40 10.6% 3.71 Top side adhesive layer (eg, adhesive layer 109) 2.5 0.7% 0.245 Top core wrap material (e.g., Material 103) 40 10.6% 3.71 total 378 100% 35

Table 1

The absorbent body can be carefully cut into 100 mm x 100 mm specimens using sharp scissors or another suitable cutting instrument. The sample was then placed on the empty tray with the bottom core wrapping material facing up. The sample is then weighed in grams to a scientific scale accurate to at least one hundredth of a gram. Record the total weight of the sample in grams to the nearest hundredth of a gram. To help ensure clarity of this test method, a total sample weight of 35.00 grams will be used for illustrations and calculations.

The total weight of each of the components of the absorbent core can then be calculated using the determined ratios reported in Table 1. For example, knowing that the bottom core wrap material represents 13% of the total weight of the absorbent body, it can be determined that the bottom core wrap material weighs approximately 4.62 grams for a total sample weight of 35.00 grams. Similar total weight values can be calculated for each of the components and reported in Table 1.

Next, Electrolub freeze spray (FRE400) should be sprayed onto the bottom core wrap material. While holding the reinforcement and top core wrap, the bottom core wrap is steadily and carefully peeled away from the reinforcement. Place the bottom core wrap material in the empty tray. Carefully pick up the remainder of the sample (e.g., reinforcement material and top core wrap material) and position it over the tray containing the bottom core wrap material. Then, carefully turn the combined reinforcement material and top core wrap material over so that the reinforcement material is facing down, and shake the combined material from side to side six (6) times, allowing any residual SAM not stabilized in the reinforcement material to fall out and into In a tray containing bottom core wrapping material. During shaking, the combined material should move laterally approximately 1 inch before reversing its direction, and shaking should take approximately two (2) seconds.

With the bottom core wrap material still in the pallet, in addition to any residual SAM shaken out from the combined reinforcement and top core wrap material, record the weight in grams to the nearest hundredth grams("Measured weight 1").

The reinforcement material and top core wrap material are then placed in the empty pallet with the top core wrap material facing up. Elecco freeze spray (FRE400) should then be sprayed onto the top core wrap material. While holding the reinforcement, the top core wrap material is steadily and carefully peeled away from the reinforcement. With the reinforcement still in the pallet, record the weight in grams to the nearest hundredth of a gram ("Measured Weight 2").

Finally, calculation can be performed to determine that the SAM particles of the absorbent body are stabilized in the various components of the absorbent body or are stabilized to the percentage of the various components of the absorbent body. In order to determine the percentage of the SAM particles stabilized to the bottom core wrapping material (for example, by the amount of the SAM particles stabilized by adhesive layer 105), the following calculation can be performed. The definite weight (for example, 0.245g in the ongoing example) of the bottom side adhesive layer and the definite weight (for example, 3.71g in the ongoing example) of the top core wrapping material can be deducted from the measured weight 1. Since the measured weight 1 is composed of the weight of the bottom core wrapping material of the sample, the bottom adhesive layer that adheres to the bottom core wrapping material, the SAM particles stabilized by the bottom adhesive layer and the residual SAM particles (which are shaken out from the reinforcer) that are not stabilized in the reinforcer, the resulting value is the weight (in grams) of the SAM particles weighed when obtaining the measured weight 1 value. This resulting value can then be divided by the definite gross weight (for example, 22.2g in the ongoing example) of the SAM particles in the sample, to obtain the percentage of the SAM at the bottom core wrapping material place stabilized in the sample.

To determine the percentage of SAM particles stabilized within the reinforcement material, the following calculation can be performed. The determined weight of the reinforcement material (eg, 3.71 g in the ongoing example) can be subtracted from the measured weight2 value. Since the Measured Weight 2 value only includes the reinforcement (including the SAM particles stabilized within the reinforcement), the resulting calculation returns the total weight of the SAM particles stabilized within the reinforcement. This total weight of SAM particles stabilized within the reinforcement material can then be divided by the determined total weight of SAM particles in the sample (e.g., 22.2 g in the ongoing example) to give the reinforcement material stabilized in the sample The percentage of SAM in .

Finally, to determine the percentage of SAM particles stabilized at the top core wrap material, one can subtract the determined total weight of SAM particles at the bottom core wrap material from the determined total weight of SAM particles in the sample (e.g., 22.2 g in the ongoing example) The determined total weight of the SAM particles at and the determined total weight of the SAM particles stabilized within the reinforcement material. This resulting calculated weight of SAM particles stabilized at the top core wrap material can then be divided by the determined total weight of SAM particles in the sample to obtain the percentage of SAM particles stabilized at the top core wrap material.

Test method for height of reinforced material after cutting:

The material to be measured may be a raw material purchased directly from the manufacturer before being applied to the product or a raw material obtained from the product of which the material is a component. Where material needs to be cut to fit test equipment, the material should be cut to a size of not less than 90mm x 102mm (3.5 inches by 4 inches). If the material is cut before testing, the material should be allowed to sit for at least twenty minutes before performing the test. Test conditions may be in accordance with ASTM E 171-187, Standard Atmospheres for Conditioning and Testing Materials, 1994.

Test equipment can be Bulk tester, and testing can be performed at a controlled load pressure of approximately 0.345 kPa (0.05 pounds force per square inch (psi)). Can record output data, accurate to 0.01mm. However, substantially equivalent equipment and settings may be employed instead. /> The minimum line pressure of the bulk tester should be 4.2kg/cm ² (60psi) and should not exceed 4.55kg/cm ² (65psi). The pressure from the foot pedal to the cylinder should be adjusted to 207kPa (30psi). A 76.2mm (3-inch) pressure plate should be used. The descent speed should be adjusted to 3 seconds ± 0.5 seconds. Next, the indicator should be turned on and reset to zero by pressing the ZERO button. Finally, the foot pedal should be depressed and the test material placed on the base, using the foot pedal to lower the platen. After 3 seconds, the displayed value should be read and recorded. This recorded value represents the expected height value of the test material (sometimes called bulk material or thickness).

Example absorption body:

Certain embodiments of absorbent body 54 have been found to be particularly advantageous in accordance with aspects of the present disclosure. According to a first preferred embodiment, the absorbent body 54 may include a top cover material 103 formed from a tissue material, an SMS material, or a spunbond material having a basis weight between about 7 gsm and about 20 gsm. The bottom cover material 101 of this first preferred embodiment may be formed from a coform or spunlace material having a basis weight between about 30 gsm and about 40 gsm. The reinforcement material 116 of this first preferred embodiment may be composed of polyolefin bicomponent fibers having a basis weight between about 40 gsm and about 50 gsm. The SAM may be applied to create an average basis weight within the body 54 of this first preferred embodiment of between about 195 gsm and about 225 gsm.

According to a second preferred embodiment, the absorbent body 54 may include a top cover material 103 formed from a tissue material, an SMS material, or a spunbond material having a basis weight between about 7 gsm and about 20 gsm. The bottom cover material 101 of this second preferred embodiment may be formed from coform, spunlace, or a basis weight between about 40 gsm and about 50 gsm. Material formation. The reinforcement material 116 of this second preferred embodiment may be a polyolefin hybrid bicomponent and eccentric fiber material having a basis weight between about 40 gsm and about 50 gsm. The SAM may be applied to create an average basis weight within the body 54 of this second preferred embodiment of between about 205 gsm and about 240 gsm.

According to a third preferred embodiment, the absorbent body 54 may include a top cover material 103 formed from a tissue material, an SMS material, or a spunbond material having a basis weight between about 7 gsm and about 20 gsm. The bottom cover material 101 of this third preferred embodiment may be formed from a coform, spunlace, or airlaid material having a basis weight between about 40 gsm and about 50 gsm. The reinforcement material 116 of this third preferred embodiment may be a polyolefin hybrid bicomponent and eccentric fiber material having a basis weight between about 40 gsm and about 50 gsm. The SAM may be applied to create an average basis weight within the body 54 of this third preferred embodiment of between about 225 gsm and about 255 gsm.

According to a fourth preferred embodiment, the absorbent body 54 may include a top cover material 103 formed from a coform, spunlace, or airlaid material having a basis weight between about 35 gsm and about 55 gsm. The bottom cover material 101 of this fourth preferred embodiment may be formed from a coform or spunlace material having a basis weight between about 35 gsm and about 45 gsm. The reinforcement material 116 of this fourth preferred embodiment may be a polyolefin eccentric fiber material having a basis weight between about 30 gsm and about 40 gsm. The SAM may be applied to create an average basis weight within the body 54 of this fourth preferred embodiment of between about 100 gsm and about 130 gsm.

All documents cited in the specific embodiments are hereby incorporated by reference in relevant part; citation of any document should not be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of a term in a document incorporated by reference, the meaning or definition assigned to the term in this written document shall control.

Those skilled in the art will recognize that the present disclosure may be embodied in many forms other than the specific embodiments described and contemplated herein. In particular, various features described in connection with various embodiments and figures should not be construed as applying only to these embodiments and/or figures. Rather, each feature described may be combined with any other feature in the various embodiments contemplated with or without any other feature described in conjunction with such feature. Accordingly, departures may be made in form and detail without departing from the scope of the disclosure as set forth in the appended claims.

implementation plan :

Embodiment 1: The method of forming an absorbent body may include: moving a first cover material in a longitudinal direction, the first cover material having a top side and a bottom side; moving a reinforcing material in the longitudinal direction, and combining the reinforcing material with the first cover material, the The reinforcement material has a top side and a bottom side; an absorbent material containing superabsorbent particles is applied to the top side of the reinforcement material; a second covering material is moved longitudinally, the second covering material having a top side and a bottom side, and the second covering material is The material is combined with the first covering material and the reinforcing material to form a laminate structure of the first covering material, the reinforcing material and the second covering material, wherein the first covering material is disposed under the reinforcing material and the second covering material is disposed under the reinforcing material the top; and embossing the laminate structure.

Embodiment 2: The method of Embodiment 1, wherein embossing the laminate structure may include embossing a top side of the laminate structure.

Embodiment 3: The method of Embodiment 1, wherein embossing the laminate structure may include embossing the second cover material.

Embodiment 4: The method of any one of embodiments 1 to 3, further comprising applying an adhesive to the top side of the first covering material and the bottom side of the reinforcing material. one and applying an adhesive to one of the top side of the reinforcing material and the bottom side of the second covering material.

Embodiment 5: The method of any one of embodiments 1 to 4, wherein the laminated structure may include a laminated region, and wherein embossing the laminated structure may include forming a layer that is larger than the laminated area. An embossed area that is about 0% of the area and less than about 42% of the laminated area.

Embodiment 6: The method of any one of embodiments 1 to 4, wherein the laminated structure may include a laminated region, and wherein embossing the laminated structure may include forming a layer that is larger than the laminated area. An embossed area that is about 5% of the area and less than about 35% of the laminate area.

Embodiment 7: The method of any one of embodiments 1 to 4, wherein the laminated structure may include a laminated region, and wherein embossing the laminated structure may include forming a layer that is larger than the laminated area. An embossed area that is about 10% of the area and less than about 30% of the laminated area.

Embodiment 8: The method of any one of embodiments 1 to 7, wherein the laminate structure may have a thickness, and wherein embossing the laminate structure may comprise embossing the laminate structure to a depth less than about 90% of the thickness of the laminate structure.

Embodiment 9: The method of any one of embodiments 1 to 7, wherein the laminate structure may have a thickness, and wherein embossing the laminate structure may comprise embossing the laminate structure to a depth less than about 80% of the thickness of the laminate structure.

Embodiment 10: The method of any one of embodiments 1 to 9, wherein the laminate structure may have a thickness, and wherein embossing the laminate structure may comprise embossing the laminate structure to a depth greater than about 40% of the thickness of the laminate structure.

Embodiment 11: The method of any one of embodiments 1 to 10, wherein embossing the laminated structure may comprise passing the laminated structure through a first embossing roller and a second embossing roller. An embossing nip is formed, the first embossing roller includes a plurality of embossing elements protruding from the surface of the first embossing roller, wherein the height of the embossing elements is between about 0.8 mm and about 4.0 mm. between.

Embodiment 12: The method of any one of embodiments 1 to 11, further comprising inverting the laminate structure.

Embodiment 13: The method of any one of embodiments 1 to 12, further comprising coupling the absorbent body to an absorbent article backsheet such that the first cover material forms a body-facing side of the absorbent body .

Embodiment 14: The method of any one of embodiments 1 to 13, further comprising applying an absorbent material comprising superabsorbent particles to the top side of the first cover material.

Embodiment 15: The absorbent body can include: a liquid permeable top cover material; a bottom cover material; a reinforcement material disposed between the top cover material and the bottom cover material; and a superabsorbent material with a high Patterns of SAM concentration areas and low SAM concentration areas are provided within the reinforcement material.

Embodiment 16: The absorbent body of Embodiment 15, wherein the region of high SAM concentration may be surrounded by the region of low SAM concentration.

Embodiment 17: The absorbent body of any one of embodiments 15 and 16, wherein the regions of high SAM concentration and the regions of low SAM concentration may form alternating stripes within the reinforcement material.

Embodiment 18: An absorbent body as described in any of Embodiments 15 to 17, wherein about 30 weight percent to about 85 weight percent of the total amount of superabsorbent material disposed between the top cover material and the bottom cover material can be stabilized within the reinforcement material as determined according to the SAM Stable Position Test Method.

Embodiment 19: The absorbent body of any one of embodiments 15 to 18, wherein said total amount of superabsorbent material disposed between said top cover material and said bottom cover material is less than about 10% by weight % can be stabilized by the first adhesive layer, as determined according to the SAM Stable Position Test Method.

Embodiment 20: The absorbent body of any one of embodiments 15 to 19, wherein the high SAM concentration areas may correspond to embossed areas of the reinforcement material.

Embodiment 21: A method of forming an absorbent body can include: moving a first cover material in a longitudinal direction, the first cover material having a top side and a bottom side; moving a reinforcing material in the longitudinal direction, and connecting the reinforcing material to the A first covering material is combined, the reinforcing material having a top side and a bottom side; an absorbent material containing superabsorbent particles is applied to the top side of the reinforcing material; a second covering material is moved along the longitudinal direction, and the The second covering material is combined with the first covering material and the reinforcing material to form a laminate structure of the first covering material, the reinforcing material and the second covering material, wherein the first covering material Material is disposed below the reinforcing material, and the second cover material is disposed on top of the reinforcing material; and the reinforcing material is embossed.

Embodiment 22: The method of Embodiment 21, wherein embossing the reinforcement material includes combining the second cover material with the first cover material and the reinforcement material to form the first The laminate structure of the covering material, the reinforcing material and the second covering material is preceded by embossing the reinforcing material.

Embodiment 23: The method of any one of embodiments 21 and 22, wherein embossing the reinforcement material includes embossing the top side of the reinforcement material.

Embodiment 24: The method of any one of embodiments 21 to 23, further comprising embossing the second covering material, wherein the embossing of the second covering material and the reinforcing material occurs simultaneously .

Embodiment 25: The method of any one of embodiments 21 to 24, further comprising applying an adhesive into the top side of the first cover material and the bottom side of the reinforcing material and applying an adhesive to one of the top side of the reinforcing material and the bottom side of the second covering material.

Embodiment 26: The method of any one of Embodiments 21 to 25, wherein the reinforcing material may include regions of reinforcing material, and wherein embossing the reinforcing material may comprise forming an area greater than about 0% and less than approximately 42% of the embossed area of the reinforcement material.

Embodiment 27: The method of any one of embodiments 21 to 26, wherein the reinforcing material can include a region of reinforcing material, and wherein embossing the reinforcing material can comprise forming a region that is larger than the region of reinforcing material. An embossed area of about 5% and less than about 35% of the reinforcement area.

Embodiment 28: The method of any one of embodiments 21 to 26, wherein the reinforcing material may comprise a region of reinforcing material, and wherein embossing the reinforcing material may comprise forming a region that is larger than the region of reinforcing material. An embossed area of approximately 10% and less than approximately 30% of the reinforcement area.

Embodiment 29: The method of any one of embodiments 21 to 28, wherein the reinforcing material can have a thickness, and wherein embossing the reinforcing material can comprise embossing the reinforcing material to be less than the thickness. The depth is approximately 90% of the thickness of the reinforcement material.

Embodiment 30: The method of any one of embodiments 21 to 28, wherein the reinforcing material can have a thickness, and wherein embossing the reinforcing material can comprise embossing the reinforcing material to be less than the thickness. The depth is approximately 80% of the thickness of the reinforcement material.

Embodiment 31: The method of any one of embodiments 21 to 30, wherein the reinforcing material may have a thickness, and wherein embossing the reinforcing material may comprise embossing the reinforcing material to a thickness greater than the thickness of the reinforcing material. The depth is approximately 40% of the thickness of the reinforcement material.

Claims (18)

1. A method of forming an absorbent body, the method comprising: moving a first covering material longitudinally, the first covering material having a top side and a bottom side; moving a reinforcing material along the longitudinal direction and combining the reinforcing material with the first cover material, the reinforcing material having a top side and a bottom side, the reinforcing material comprising a bonded nonwoven material containing polyolefin fibers; applying an absorbent material containing superabsorbent particles to the top side of the reinforcement material; moving a second covering material along the longitudinal direction, the second covering material having a top side and a bottom side, and bonding the second covering material to the first covering material and the reinforcing material, wherein an adhesive is Applied between a second covering material and a reinforcing material with applied superabsorbent particles to form the first covering material, the reinforcing material with applied superabsorbent particles and the second covering material a laminate structure, wherein the first cover material is disposed below the reinforcement material and the second cover material is disposed on top of the reinforcement material; and The laminate structure is embossed, the laminate structure comprising greater than or equal to 90% by weight of the superabsorbent material, wherein the absorbent material is patterned in a pattern of areas of high superabsorbent particle concentration and areas of low superabsorbent particle concentration. The high superabsorbent particle concentration zone is disposed within the reinforcing material and corresponds to the embossed area of the reinforcing material. 2. The method of claim 1, wherein embossing the laminate structure includes embossing a top side of the laminate structure. 3. The method of claim 1, wherein embossing the laminate structure includes embossing the second cover material. 4. The method of claim 1, further comprising: applying an adhesive to one of the top side of the first cover material and the bottom side of the reinforcement material; and An adhesive is applied to one of the top side of the reinforcement material and the bottom side of the second cover material. 5. The method of claim 1, wherein the laminated structure includes a laminated area, and wherein embossing the laminated structure includes forming greater than 0% of the laminated area and less than 0% of the laminated area. 42% of the area is embossed. 6. The method of claim 1, wherein the laminated structure includes a laminated area, and wherein embossing the laminated structure includes forming greater than 5% of the laminated area and less than 5% of the laminated area. 35% of the embossed area. 7. The method of claim 1, wherein the laminated structure includes a laminated area, and wherein embossing the laminated structure includes forming greater than 10% of the laminated area and less than 10% of the laminated area. 30% of the embossed area. 8. The method of claim 1, wherein the laminate structure has a thickness, and wherein embossing the laminate structure includes embossing the laminate structure to less than 90% of the thickness of the laminate structure. %depth. 9. The method of claim 1, wherein the laminate structure has a thickness, and wherein embossing the laminate structure includes embossing the laminate structure to less than 80% of the thickness of the laminate structure. %depth. 10. The method of claim 1, wherein the laminate structure has a thickness, and wherein embossing the laminate structure includes embossing the laminate structure to a thickness greater than 40% of the thickness of the laminate structure. %depth. 11. The method of claim 1, wherein embossing the laminated structure includes passing the laminated structure through an embossing nip formed by a first embossing roller and a second embossing roller, the The first embossing roller includes a plurality of embossing elements protruding from the surface of the first embossing roller, wherein the height of the embossing elements is between 0.8 mm and 4.0 mm. 12. The method of claim 1, further comprising inverting the laminate structure. 13. The method of claim 1, further comprising coupling the absorbent body to an absorbent article backsheet such that the first cover material forms a body-facing side of the absorbent body. 14. The method of claim 1, further comprising applying an absorbent material containing superabsorbent particles to the top side of the first cover material. 15. An absorbent body, comprising: Liquid permeable top covering material; Bottom covering material; a reinforcing material disposed between the top covering material and the bottom covering material, the reinforcing material comprising a bonded nonwoven material containing polyolefin fibers; and A superabsorbent material disposed within the reinforcement material in a pattern of high SAM concentration areas and low SAM concentration areas, wherein the high SAM concentration areas correspond to embossed areas of the reinforcement material; wherein the top covering material, the reinforcing material and the bottom covering material form a laminate structure, the laminate structure comprising greater than or equal to 90% by weight of the absorbent material of superabsorbent material; Wherein 30% to 85% by weight of the total amount of superabsorbent material disposed between the top cover material and the bottom cover material is stabilized within the reinforcement material, as determined according to the SAM Stable Position Test Method. 16. The absorbent body of claim 15, wherein the high SAM concentration region is surrounded by the low SAM concentration region. 17. The absorbent body of claim 15, wherein the regions of high SAM concentration and the regions of low SAM concentration form alternating stripes within the reinforcement material. 18. The absorbent body of claim 15, wherein less than 10% by weight of the total amount of superabsorbent material disposed between the top cover material and the bottom cover material is stabilized by a first adhesive layer, such as Measured according to SAM stable position test method.